Spirit XE526SE, Service Manual

Page 1: ...Service Manual Elliptical XE526SE ...

Page 2: ...Front Rear Round Disk Cover Console Pedal R Side Case R Left Handle Bar Cover Front Rear Console Mast Cover Pedal Arm Cover L Rear Stabilizer Cover A Connecting Arm Cover B R Slide Wheel Cover Rear Stabilizer Cover B Connecting Arm Cover A L Pedal L Front Stabilizer Cover Side Case L ...

Page 3: ...Skeleton Cross Bar Bushing Housing Connecting Arm R Console Mast Swing Arm R Main Frame Rear Rail Assembly Flywheel Pedal Arm L Pedal Arm R Drive Pulley Connecting Arm L Slide Wheel ...

Page 4: ... The Idler Wheel Assembly 8 The Flywheel 9 The Drive Pulley 10 The Bushing Housing 11 Slide Wheels II Troubleshooting 1 The Console 2 Side Cases and Round Disk 3 The Flywheel 4 The Drive Belt 5 Swing Arms 6 The Bushing Housing 7 Pedal Arms Connecting Arms and Slide Wheels III Q A 1 Noises 2 Slippage 3 Plays 4 Smoothness 5 Other Problems ...

Page 5: ... cable handle wire red and white and hand pulse cable in order to take the console apart as shown in figures 1 2 2 To resume connect the computer cable handle wire red and white and hand pulse cable with the console and tighten four M5 x 10 mm Phillips head screws beware not to twist cables 3 If taking apart the console bottom cover is necessary release 3 5x12 self tapping screws as shown in figur...

Page 6: ... self tapping screws which secure connecting arm covers as shown in figures 1 2 2 Then use 12mm and 13mm wrenches to release 5 16 x1 1 4 hex head screw 5 16 x 20 x 1 5T flat washer and 5 16 x 7T nut which secure the rod end bearing as shown in figure 3 3 Use 12mm wrench to release 5 16 x 15m m hex head screw and 5 16 x 23 x1 5T flat washer which secure the swing arm to take it apart as shown in fi...

Page 7: ...arm then release the carriage bolt under the pedal to take the connecting arm apart as shown in figure 5 5 Release four M5x10mm Phillips head screws which secure the pedal to take the pedal from the connecting arm as shown in figure 6 6 Reverse above procedures to resume parts by returning the carriage bolt and tightening 5 16 x 15m m hex head screw and 5 16 x 23 x 1 5T flat washer as shown in fig...

Page 8: ...e 3 8 x 2 1 4 Socket Head Cap Bolt two 3 8 19 1 5T flat washers and 3 8 x 11T nut which secure the pedal arm and bushing housing and take the pedal apart as shown in figures 2 3 3 Use 12mm wrench to release 5 16 x 15m m hex head screw and 5 16 x 35 x1 5T flat washer and take the bushing housing apart as shown in figure 4 4 Reverse above steps to resume parts 1 2 3 4 ...

Page 9: ...arate from side covers as shown in figure 1 3 Use Phillips head screw driver to release seven 4x19 self tapping screws and three 5x16 tapping screws which secure right side case to take it apart as shown in figures 2 3 4 To take left side case apart release 4x15 self tapping screws 1 4 x19 flat washers and three 5x16 tapping screws on the main frame then disconnect DC cables as shown in figures 4 ...

Page 10: ...etween the side case and the main frame then tighten three 5x16 tapping screws with the side case and round disk at the center and 4x15 self tapping screws as shown in figure 7 8 7 Match right side case with left side case and tighten with seven 4x19 self tapping screws and three 5x16 tapping screws 8 Follow procedures 3 4 and 2 5 to resume the pedal arm and the connecting arm 5 6 7 8 ...

Page 11: ... x 15m m hex head screw and 5 16 x 35 x 1 5T flat washer then use M6 wrench and 13mm wrench to release M8x40 Socket Head Cap Bolt and two M8x6 3T nuts in order to take the cross bar and the drive pulley apart as shown in figures 2 3 4 To separate the cross bar from the drive pulley take apart the bushing housing first then use Phillips head screw driver to release eight 5x16 tapping screws and 1 4...

Page 12: ...turn it on the crank axle insert 7x7x25L Woodruff Key and tighten M8x40 Socket Head Cap Bolt with M8x6 3T nuts until 500 kg f of torque then tighten 5 16 x 15m m hex head screw with 5 16 x 35 x 1 5T flat washer as shown in figures 5 6 6 Follow procedures 4 3 and 2 to return the connecting arm pedal arm and side covers with round disk cover 5 6 ...

Page 13: ...M8 x 9T nut on M8x170mm J bolt and M8 x 7T nut on idler wheel assembly in order to take the belt apart as shown in figures 1 2 3 3 To resume first return the belt on the drive pulley and the flywheel and tighten M8 x 9T nut Make sure the belt is as tight as the sound wave gauge reads 170 10 Hz before tightening up M8 x 7T nut as shown in figure 4 4 Follow procedures 5 4 3 and 2 to return all parts...

Page 14: ...5 16 x 23 x 1 5T flat washer on M8x170mm J bolt and take the J bolt apart Then use again 13mm wrench to release M8 x 20 carriage bolt 5 16 x 20 x 1 5T flat washer and M8 x 7T nut which secure the idler wheel assembly to take it apart as shown in figures 1 2 3 To take apart the bearing of the idler wheel Use C clip pliers to release ψ17 C ring on the axle and 6203 bearing can thus be taken apart 4 ...

Page 15: ...ing arm pedal arm side cases the cross bar and the belt together with the idler wheel assembly 2 Plug in the power adjust the resistance to level 20 and take apart the steel cable as shown in figures 1 2 3 Use 15mm wrench to loosen two 3 8 UNF26 x 9T nuts and pull out the flywheel Take apart the belt as shown in figures 3 4 1 2 3 4 ...

Page 16: ... UNF26 x 9T nuts 6 Return the steel cable on the flywheel and install the idler wheel assembly as shown in figure 5 7 Turn the drive pulley and adjust both 3 8 UNF26 x 4T nuts to assure the belt locates at the center of the drive pulley to make sure the belt does not fall off and tighten the screws Adjust the belt for proper tension as shown in figure 6 8 Reverse above ateps to resume all parts 5 ...

Page 17: ...the crank axle and the drive pulley as shown in figures 1 2 use rubber hammer to take off the crank axle if necessary 3 To separate the axle from the drive pulley use C ring pliers to release ψ25 C ring on the axle and then use 11mm wrench to release four 1 4 x 3 4 hex head screws and 1 4 nuts as shown in figure 3 4 To resume install the drive pulley and a C ring on the axle and return onto the ma...

Page 18: ...ex head screw and 5 16 x 35 x 1 5T flat washer and take apart the bushing housing as shown in figure 1 3 To resume return in order the plastic wave washer and ψ25 wave washer onto the axle then install the bushing housing on the axle and secure with 5 16 x15m m hex head screw and 5 16 x 35 x 1 5T flat washer as shown in figure 2 4 Reverse above steps to return the pedal arm and the connecting arm ...

Page 19: ...rt as shown in figure 1 2 Use C ring pliers to release ψ17 C ring and take apart the slide wheel as shown in figure 2 3 To resume return in order ψ17 wave washer slide wheel and ψ17 wave washer and secure with a C ring Return the slide wheel cover as shown in figure 3 4 Reverse above steps to return the pedal arm and the connecting arm 1 2 3 ...

Page 20: ...s plug in and the other end is insert to the unit as shown in figure 1 3 Make sure all harnesses are properly connected including the console and computer cable computer cable and DC cables which can be done by disassembling the console 4 If harnesses are properly connected check for the damage of harness console malfunction or gear motor malfunction as shown in figures 2 3 1 2 3 ...

Page 21: ...ff center take it apart and resume according to the procedure 4 for replacing side cases 3 If the round disk swings with too much displacement take apart side cases and the round disk and use Phillips head screw driver to release 16pcs of 5x16mm tapping screws and 1 4 x19mm flat washers Put the round disk with cross bar on the platform and check any deforms Deform can be corrected with force The d...

Page 22: ...oise cause by improper adjustment of the steel cable or improper installation Follow the section of replacing flywheel and the belt for adjustment as shown in figure 1 2 If there is noise with the flywheel check if there is foreign material or abnormal rubbing Replace with new flywheel if the noise can not be fixed as shown in figure 2 1 2 ...

Page 23: ...alignment of the belt drive pulley and the flywheel Then turn the drive pulley with the speed between 100 and 120 rpm with sudden stop If the belt runs normally resume all parts as shown in figure 1 2 If the belt drive pulley and the flywheel do not align well adjust the flywheel to the proper position as shown in figure 2 3 If the belt slips refer to procedure 6 and use 13mm wrench to adjust the ...

Page 24: ... assembly by the user and it is normal with slight play Noises might be caused due to these tolerances after certain time of usage It is recommended to add heavy viscosity lubricant on ψ25x296L console mast shaft for the swing arm as shown in figure 1 2 If the bearing is making noises or being stuck replace bearing 6005 as shown in figure 2 3 1 2 3 ...

Page 25: ...this portion is rare Occasionally there is noise after very long duration of usage When this occurs apply some heavy viscosity lubricant on ψ25 x 111 5 L clank axle which is on the cross bar as shown in figure 1 2 If the plastic bushing has been worn out replace with a new one as shown in figure 2 1 2 ...

Page 26: ...ted to each other and proper lubrication is important Lubricating with heavy viscosity lubricant while maintenance can eliminate potential problems as shown in figures 1 2 2 There are many causes for un smoothness Slide wheels moving parallel and freely on the rail is the key factor which is affected by the pedal arm parallel to the rail and perpendicular to the bearing housing 1 2 ...

Page 27: ...freely to connecting arms the true circle of slide wheels without slippage 4 For maintenance start from slide wheels by replacing them or applying some lubricant on the curvature on the slide wheels Keep parallel parts parallel to each other is the key to judge which part need to be adjusted or replaced as shown in figures 3 4 3 4 ...

Page 28: ...lt and the drive pulley idler wheel handle bar and console mast shaft flywheel and the steel cable concerning the front portion of the elliptical to the rear portion such as slide wheels and clank axle with wave washers pedal arms and pedals Major causes for noises are insufficient lubricant un smoothness and loose screws Since those are moving parts and interactively problem solving must be treat...

Page 29: ...s shown in figure 1 3 Bushing housing 3 8 x1 1 4 Socket Head Cap Screw and 3 8 x 11T nut on top must be tight enough as shown in figure 2 4 Cross Bar M8x40m m Socket Head Cap Screw on the cross bar must be tight enough with the nut 5 The Belt This case occurs most frequently as the belt gets loose after certain time of usage depending on the duration and weight of the user Refer to procedure 6 rep...

Page 30: ... tightening all screws is the first step to fix the problem of play Wearing at the joint and improper installation lead to loose screws Play of the pedal may caused by improper installation of the carriage bolt Play of the whole unit can be fixed by adjusting foot pad screw as shown in figures 1 and 2 1 2 ...

Page 31: ...v Procedures 1 If there are clicks felt make sure all screws are tight enough 2 The un smoothness might be caused by foreign material sticky on the rail or on the slide wheel Wipe with alcohol then apply lubricant on the rail as shown in figure 1 1 ...

Page 32: ... of elliptical problems it describes most of it Whatever the problem occurs fixing the problem is back up by Dyaco technical service Although this manual can not cover all of elliptical problems it describes most of it Whatever the problem occurs fixing the problem is back up by Dyaco technical service ...